Fluid monitoring module arrangements

ABSTRACT

A flow sensing device includes a first body member defining an inlet port, an upstream sensor port, and a first connecting port; a second body member defining an outlet port, a downstream sensor port, and a second connecting port; a flow restricting element defining a flow restricting passage and including a first end connection coupled to the first connecting port and a second end connection coupled to the second connecting port, such that the flow restricting passage is disposed between the inlet port and the outlet port, and between the upstream sensor port and the downstream sensor port; a first fluid sensor assembled with the upstream sensor port; and a second fluid sensor assembled with the downstream sensor port.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 16/573,289, filed on Sep. 17, 2019, for FLUIDMONITORING MODULE ARRANGEMENTS which claims the benefit of U.S.Provisional Patent Application Ser. No. 62/732,848, filed on Sep. 18,2018 and entitled LAMINAR FLOW ELEMENT, U.S. Provisional PatentApplication Ser. No. 62/775,066, filed on Dec. 4, 2018 and entitled FLOWSENSING MODULE, U.S. Provisional Patent Application Ser. No. 62/844,383,filed on May 7, 2019 and entitled FLUID MONITORING MODULE ARRANGEMENTS,U.S. Provisional Patent Application Ser. No. 62/844,390, filed on May 7,2019 and entitled FLUID MONITORING MODULE ARRANGEMENTS, U.S. ProvisionalPatent Application Ser. No. 62/844,399, filed on May 7, 2019 andentitled FLUID MONITORING MODULE ARRANGEMENTS, and U.S. ProvisionalPatent Application Ser. No. 62/895,115, filed on Sep. 3, 2019 andentitled FLUID MONITORING MODULE ARRANGEMENTS, the entire disclosures ofeach of which are incorporated herein by reference.

BACKGROUND

Laminar flow elements (or LFEs) are generally used to measure the flowof gases, for example, for use with mass flowmeters or other suchmonitoring devices. A conventional laminar flow element operates byproducing a differential pressure that is proportional to the velocityof the gas passing through a section of the laminar flow element, whichis specifically configured to maintain the gas flow in a laminar state.Upstream and downstream pressure sensors detect this pressuredifferential, which is used to calculate the flow rate. Due to thetypical length-to-diameter requirements of the restricting flow path ofa laminar flow element (e.g., a 25:1 ratio), large size, intricatemachining, or complex assembly requirements often result in increasedmanufacturing costs, extensive lead times, and/or undesirably large LFEcomponents.

SUMMARY

According to an aspect of the present disclosure, a flow sensing deviceincludes a first body member defining an inlet port, an upstream sensorport, and a first connecting port; a second body member defining anoutlet port, a downstream sensor port, and a second connecting port; aflow restricting element defining a flow restricting passage andincluding a first end connection coupled to the first connecting portand a second end connection coupled to the second connecting port, suchthat the flow restricting passage is disposed between the inlet port andthe outlet port, and between the upstream sensor port and the downstreamsensor port; a first fluid sensor assembled with the upstream sensorport; and a second fluid sensor assembled with the downstream sensorport.

According to another aspect of the present disclosure, a fluidmonitoring module includes a flow sensing device and a controller. Theflow sensing device includes a first body member defining an inlet port,an upstream sensor port, and a first connecting port; a second bodymember defining an outlet port, a downstream sensor port, and a secondconnecting port; a flow restricting element defining a flow restrictingpassage and including a first end connection coupled to the firstconnecting port and a second end connection coupled to the secondconnecting port, such that the flow restricting passage is disposedbetween the inlet port and the outlet port, and between the upstreamsensor port and the downstream sensor port; a first fluid sensorassembled with the upstream sensor port; and a second fluid sensorassembled with the downstream sensor port. The controller is in circuitcommunication with the first and second fluid sensors for receiving atleast one of pressure indicating signals and temperature indicatingsignals from each of the first and second fluid sensors, and formeasuring fluid data based on the received signals.

According to another aspect of the present disclosure, a fluidmonitoring module includes an enclosure, a fluid sensing deviceassembled with the enclosure, and a controller disposed within theenclosure. The fluid sensing device includes a first body memberdefining a first end port, a first sensor port, and a first connectingport; a second body member defining a second end port, a second sensorport, and a second connecting port; a first fluid sensor assembled withthe first sensor port; and a second fluid sensor assembled with thesecond sensor port. The controller is in circuit communication with thefirst and second fluid sensors for receiving at least one of pressureindicating signals and temperature indicating signals from each of thefirst and second fluid sensors, and for measuring fluid data based onthe received signals. The first end port, the second end port, the firstconnecting port, and the second connecting port are external to theenclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages and benefits will become apparent to those skilled inthe art after considering the following description and appended claimsin conjunction with the accompanying drawings, in which:

FIG. 1 is a cross-sectional view of an exemplary flow sensing device, inaccordance with an aspect of the present disclosure;

FIG. 1A is a perspective view of the flow sensing device of FIG. 1;

FIG. 1B is a side view of a multiple flow sensing device system, inaccordance with another aspect of the present disclosure;

FIG. 2 is a cross-sectional view of an exemplary flow sensing device, inaccordance with another aspect of the present disclosure;

FIG. 3 is a cross-sectional view of an exemplary flow sensing device, inaccordance with another aspect of the present disclosure;

FIG. 4 is a cross-sectional view of an exemplary flow sensing device, inaccordance with another aspect of the present disclosure;

FIG. 5 is a cross-sectional view of an exemplary flow sensing device, inaccordance with another aspect of the present disclosure;

FIG. 6 is a cross-sectional view of an exemplary flow sensing device, inaccordance with another aspect of the present disclosure;

FIG. 7 is a cross-sectional view of an exemplary flow sensing device, inaccordance with another aspect of the present disclosure;

FIG. 8 is a schematic view of a flow sensing device, in accordance withanother aspect of the present disclosure;

FIG. 9 is a schematic view of another flow sensing device, in accordancewith another aspect of the present disclosure; and

FIG. 10A is a front perspective view of an exemplary wireless fluidmonitoring module, in accordance with another aspect of the presentdisclosure;

FIG. 10B is a rear perspective view of the wireless fluid monitoringmodule of FIG. 10A;

FIG. 10C is an exploded perspective view of the wireless fluidmonitoring module of FIG. 10A;

FIG. 11A is a side cross-sectional view of the wireless fluid monitoringmodule of FIG. 10A;

FIG. 11B is a top cross-sectional view of the wireless fluid monitoringmodule of FIG. 10A;

FIG. 12 is a side cross-sectional view of another exemplary wirelessfluid monitoring module, in accordance with another aspect of thepresent application;

FIG. 13A is a perspective view of another exemplary wireless fluidmonitoring module, in accordance with another aspect of the presentdisclosure;

FIG. 13B is a perspective view of another exemplary wireless fluidmonitoring module, in accordance with another aspect of the presentdisclosure;

FIG. 13C is a perspective view of another exemplary wireless fluidmonitoring module, in accordance with another aspect of the presentdisclosure;

FIG. 14 is a schematic view of a fluid monitoring module, in accordancewith another aspect of the present disclosure;

FIGS. 14A-141 are cross-sectional views of exemplary flow restrictingelements for a fluid monitoring module, in accordance with anotheraspect of the present disclosure;

FIG. 15 is a schematic view of another fluid monitoring module, inaccordance with another aspect of the present disclosure;

FIG. 16A is a side view of an exemplary wireless fluid monitoring modulehaving an external flow restricting element, in accordance with anotheraspect of the present disclosure;

FIG. 16B is a side view of another exemplary wireless fluid monitoringmodule having an external flow restricting element, in accordance withanother aspect of the present disclosure;

FIG. 16C is a side view of another exemplary wireless fluid monitoringmodule having an external flow restricting element, in accordance withanother aspect of the present disclosure;

FIG. 16D is a side view of another exemplary wireless fluid monitoringmodule having an external flow restricting element, in accordance withanother aspect of the present disclosure;

FIG. 16E is a side view of another exemplary wireless fluid monitoringmodule having an external flow restricting element, in accordance withanother aspect of the present disclosure;

FIG. 17 is a side cross-sectional view of an exemplary sensor portmounting arrangement for a wireless fluid monitoring module having anexternal flow restricting element;

FIG. 18A is a side view of an exemplary wireless fluid monitoring modulehaving a dual fluid monitoring arrangement, in accordance with anotheraspect of the present disclosure;

FIG. 18B is a side view of another exemplary wireless fluid monitoringmodule having a dual fluid monitoring arrangement, in accordance withanother aspect of the present disclosure;

FIG. 18C is a side view of another exemplary wireless fluid monitoringmodule having a dual fluid monitoring arrangement, in accordance withanother aspect of the present disclosure;

FIG. 18D is a cross-sectional perspective view of an exemplary blankcoupling connection, in accordance with another aspect of the presentdisclosure;

FIG. 18E is a cross-sectional perspective view of an exemplary couplingconnection with blank disc insert, in accordance with another aspect ofthe present disclosure;

FIG. 19 is a schematic view of a fluid system with a portable fluidmonitoring module, in accordance with another aspect of the presentdisclosure;

FIG. 20 is a schematic view of another fluid system with anotherportable fluid monitoring module, in accordance with another aspect ofthe present disclosure;

FIG. 21 is a schematic view of another fluid system with anotherportable fluid monitoring module, in accordance with another aspect ofthe present disclosure;

FIG. 22 is a schematic view of another fluid system with anotherportable fluid monitoring module, in accordance with another aspect ofthe present disclosure; and

FIG. 23 is a schematic view of an exemplary fluid monitoring and grabsampling system, accordance with another aspect of the presentdisclosure.

DETAILED DESCRIPTION

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, circuits, devices and components, software,hardware, control logic, alternatives as to form, fit and function, andso on—may be described herein, such descriptions are not intended to bea complete or exhaustive list of available alternative embodiments,whether presently known or later developed. Those skilled in the art mayreadily adopt one or more of the inventive aspects, concepts or featuresinto additional embodiments and uses within the scope of the presentinventions even if such embodiments are not expressly disclosed herein.Additionally, even though some features, concepts or aspects of theinventions may be described herein as being a preferred arrangement ormethod, such description is not intended to suggest that such feature isrequired or necessary unless expressly so stated. Still further,exemplary or representative values and ranges may be included to assistin understanding the present disclosure, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Still further,exemplary or representative values and ranges may be included to assistin understanding the present disclosure, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Parametersidentified as “approximate” or “about” a specified value are intended toinclude both the specified value and values within 10% of the specifiedvalue, unless expressly stated otherwise. Further, it is to beunderstood that the drawings accompanying the present disclosure may,but need not, be to scale, and therefore may be understood as teachingvarious ratios and proportions evident in the drawings. Moreover, whilevarious aspects, features and concepts may be expressly identifiedherein as being inventive or forming part of an invention, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificinvention, the inventions instead being set forth in the appendedclaims. Descriptions of exemplary methods or processes are not limitedto inclusion of all steps as being required in all cases, nor is theorder that the steps are presented to be construed as required ornecessary unless expressly so stated.

The Detailed Description merely describes exemplary embodiments and isnot intended to limit the scope of the claims in any way. Indeed, theinvention as claimed is broader than and unlimited by the exemplaryembodiments, and the terms used in the claims have their full ordinarymeaning. For example, while specific exemplary embodiments in thepresent disclosure describe flow sensing devices with pressure sensorsfor measuring differential pressure and correlating the differentialpressure to flow rate, in other embodiments, one or more of the featuresdescribed herein may be applied to other fluid system components,including, for example, conduit fittings and valves.

According to an aspect of the present disclosure, as illustrated in thecross-sectional view of FIG. 1, a flow sensing device 100 may beprovided with a cross-shaped body 110 including laterally extendinginlet and outlet ports 111, 112 and axially extending upstream anddownstream sensor ports 113, 114. As shown, the inlet port 111 may, butneed not, be substantially coaxial with the outlet port 112 (along axisX, as shown), and the upstream sensor port 113 may, but need not, besubstantially coaxial with the downstream sensor port 114 (along axis Y,as shown). The inlet and outlet ports 111, 112 may include any suitablefluid system connectors, including, for example, one or more tubefittings, face seal fittings, threaded pipe ends, or weld ends. Theinlet port 111 is connected in fluid communication with the upstreamsensor port 113 by an inlet branch port 116, and the outlet port 112 isconnected in fluid communication with the downstream sensor port 114 byan outlet branch port 117. The upstream and downstream sensor ports 113,114 are connected by a flow restricting passage 115 extending generallyaxially from the upstream sensor port 113 to the downstream sensor port114. While the flow restricting passage 115 may be specificallyconfigured to maintain laminar flow through the device 100 (e.g., as alaminar flow element, or LFE), in other embodiments, the flowrestricting passage may permit turbulent flow, or a combination oflaminar flow and turbulent flow, while still providing for a consistentdesired flow rate or range of flow rates. As shown, other than thebranch ports 116, 117, the body 110 may (but need not) be substantiallysymmetrical about either or both of the X and Y axes.

An upstream pressure sensor 120 is installed in the upstream sensor port113 and is configured to generate a signal corresponding to an upstreampressure, and a downstream pressure sensor 130 is installed in thedownstream sensor port and is configured to generate a signalcorresponding to a downstream pressure. The pressure sensors 120, 130may transmit signals to an electronic controller, shown schematically at150, in circuit communication with the pressure sensors, for example, bywired or wireless communication, with the electronic controller beingconfigured to evaluate the upstream and downstream pressurescorresponding to the received signals, to determine a pressuredifferential across the flow restricting passage and a correspondingflow rate through the flow sensing device 100.

The upstream and downstream pressure sensors 120, 130 may include anysuitable type of pressure sensor (e.g., a piezoresistive strain gauge, acapacitive pressure sensor, an electromagnetic pressure sensor, apiezoelectric pressure sensor), which may be securely retained withinthe corresponding sensor port 113, 114, for example, using a retainingring 121, 131, and may be sealed within the corresponding sensor port113, 114, for example, using an O-ring or gasket seal 122, 132. In anexemplary embodiment, the sensor may be configured to detect or measureboth pressure and temperature, and transmit pressure and temperatureindicating signals to the controller. The controller may be configuredto process the pressure and temperature indicating signals, for example,to determine pressure, temperature, and/or flow rate, and/or to providea measured output of any one or more of these parameters. An exemplarysensor configured to measure pressure and temperature is the LD seriespiezoresistive OEM pressure transmitter, manufactured by Keller.

The compact arrangement of the cross-shaped body 110 of the flow sensingdevice 100 may allow the flow sensing device to be incorporated intosmaller enclosures or smaller equipment, or more seamlessly intoexisting systems. While a system including a plurality of flow sensingdevices may include a separate controller connected with each of theflow sensing devices, in another embodiment, the compact flow sensingdevices may be arranged and configured for electrical connection with asingle controller. FIG. 1B illustrates an exemplary system 10 includinga plurality of flow sensing devices 100 arranged end to end, withupstream and downstream pressure sensors 120, 130 electrically connectedto the controller 150, and inlet and outlet ports 111, 112 connected toparallel fluid lines 11, 12.

Many different suitable laminar flow restricting passages may beutilized. In some embodiments, one or more flow restricting passages maybe integrally formed in the body, for example, by drilling, machining,or additive manufacturing (e.g., 3D printing). In other embodiments, oneor more flow restricting passages may be defined by a flow restrictingelement formed from one or more inserts (e.g. plugs, plates, etc.)installed in a cavity in the body between the upstream and downstreamsensor ports. This type of flow passage insert arrangement mayfacilitate formation of the flow passages, and/or may allow foradaptability of the flow sensing device, for example, by allowing fordifferent ranges of flow rate and pressure differential.

In one example, as shown in FIG. 2, a body 110 a of a flow sensingdevice 100 a includes a narrow axially extending (e.g., capillary)passage 115 a extends between the upstream sensor port 113 a and thedownstream sensor port 114 a. In another exemplary embodiment, as shownin FIG. 3, a body 110 b of a flow sensing device 100 b includes multiplenarrow axially extending passages 115 b extends between the upstreamsensor port 113 b and the downstream sensor port 114 b, for example, toprovide for increased laminar flow while limiting the axial length ofthe body 110 b.

In another exemplary embodiment, as shown schematically in FIG. 4, thebody 110 c of a flow sensing device 100 c may be provided with one ormore narrow, laminar flow restricting passages 115 c having a pluralityof coils or convolutions arranged to provide an extended passage lengthover a limited axial dimension of the body, between the upstream anddownstream sensor ports 113 c, 114 c. These convoluted or coiledpassages may be formed, for example, by additive manufacturing tofacilitate production of one or more convoluted laminar flow restrictingpassages 115 c between the upstream sensor port 113 c and the downstreamsensor port 114 c. In another exemplary embodiment, as shown in FIG. 5,the body 110 d of a flow sensing device 100 d may include a centralcavity 119 d retaining a stack of plates 140 d having holes and/or slotsaligned to define the passage(s) 115 d. In other embodiments, convolutedor selectively contoured passages (formed, for example, by additivemanufacturing) may be utilized to provide or perform other fluid flowfunctions such as, for example, mixing, swirling, heat/cold tracing orother such functionality.

In other exemplary embodiments, as shown in FIG. 6, a body 110 e of aflow sensing device 100 e may include a flow restricting element 140 e(e.g., a sintered element) installed in a cavity 119 e of the body 110 eto define a flow passage 115 e that restricts flow to a desired flowcondition (e.g., laminar flow and/or a desired flow range). An O-ring orother such gasket seal 149 e may be provided around the flow restrictingelement 140 e (e.g., in an inner peripheral groove in the body cavity119 e, and/or in an outer peripheral groove in the flow restrictingelement 140 e) may be provided around the flow restricting element toseal against leakage/flow past the periphery of the flow restrictingelement. In another exemplary embodiment, as shown in FIG. 7, the body110 f of a flow sensing device 100 f may be formed by additivemanufacturing to facilitate production of a porous, axially extendingportion 140 f of the body between the upstream and downstream sensorports 113 f, 114 f, with a pore size and density selected to provide adesired flow condition.

Flow restricting sintered elements or other such porous or narrowpassage restricting portions may tend to get blocked or clogged bycontaminants in the system fluid, which may affect system flow rates andthe flow readings provided by the device. According to another aspect ofthe present disclosure, a flow sensing device body may be provided witha flow restricting element shaped or otherwise configured to divert orcollect contaminants into a recessed portion of the body cavity, therebyminimizing the clogging or blocking of the porous flow restrictingelement.

FIG. 8 schematically illustrates an exemplary flow sensing device 1100including a body member 1110 having inlet and outlet ports 1111, 1112and upstream and downstream sensor ports 1113, 1114. The inlet andoutlet ports 1111, 1112 may include any suitable fluid systemconnectors, including, for example, one or more tube fittings, face sealfittings, threaded pipe ends, or weld ends. The inlet port 1111 isconnected in fluid communication with the upstream sensor port 1113 byan internal upstream passage 1116, and the outlet port 1112 is connectedin fluid communication with the downstream sensor port 1114 by aninternal downstream passage 1117. The upstream and downstream sensorports 1113, 1114 sealingly retain sensors 1120, 1130 and are connectedby a porous flow restricting element 1140 disposed in a cavity 1119 ofthe body 1110 to define a flow restricting passage 1115. While the flowrestricting passage 1115 may be specifically configured to maintainlaminar flow through the device 1100, in other embodiments, the flowrestricting passage may permit turbulent flow, or a combination oflaminar flow and turbulent flow, while still providing for a consistentdesired flow rate or range of flow rates.

As shown, the exemplary flow restricting element 1140 includes a conicalcentral porous portion 1141 and an outer peripheral solid or non-porousportion 1142 that forms an annular recess into which fluid contaminantsmay collect without blocking or further restricting the flow path. Theinternal upstream passage 1116 may be shaped to direct fluid flow towardthe surfaces of the body cavity 1119 and the annular recess 1142.Alternatively, as shown, an upstream end or tip 1143 of the flowrestricting element may also be solid or non-porous, and the internalupstream passage 1116 in the body 1110 may be shaped to direct fluidflow toward the solid restricting element tip, such that the contouredtip directs contaminants radially outward while minimizing any tendencyfor the contaminants to become embedded in the porous portions of theflow restricting element. Other porous element shapes may be utilizedincluding, for example, hemispherical or pyramid shaped elements. Theflow restricting element 1140 may be provided as an insert forinstallation in the body cavity 1119, similar to the embodiment of FIG.6. Alternatively, the flow restricting element 1140 may be integrallyformed with the body 1110, similar to the embodiment of FIG. 7. Ineither case the flow restricting element may be formed using additivemanufacturing (e.g., 3D printing) which may be well suited toselectively form portions of the element in porous and non-porousmaterials.

Porous restricting portions or narrow restricting passages may becomepartially blocked or clogged by condensation in a gaseous fluid system,for example, where the fluid system is subjected to lower temperaturesor sudden changes in temperature. According to another aspect of thepresent disclosure, a flow sensing device body may be provided with aflow restriction heating arrangement, for example, to selectivelyevaporate or boil off condensation, or to maintain the flow restrictingelement at temperatures that will prevent condensation, therebypreventing this type of restricting element blockage.

FIG. 9 schematically illustrates an exemplary flow sensing device 1200including a body member 1210 having inlet and outlet ports 1211, 1212and upstream and downstream sensor ports 1213, 1214. The inlet andoutlet ports 1211, 1212 may include any suitable fluid systemconnectors, including, for example, one or more tube fittings, face sealfittings, threaded pipe ends, or weld ends. The inlet port 1211 isconnected in fluid communication with the upstream sensor port 1213 byan internal upstream passage 1216, and the outlet port 1212 is connectedin fluid communication with the downstream sensor port 1214 by aninternal downstream passage 1217. The upstream and downstream sensorports 1213, 1214 sealingly retain sensors 1220, 1230 and are connectedby a flow restricting element 1240 disposed in a cavity 1219 of the body1210 and defining a flow restricting passage 1215 (e.g., one or moreformed passages or a porous flow restricting material). While the flowrestricting passage 1215 may be specifically configured to maintainlaminar flow through the device 1200, in other embodiments, the flowrestricting passage may permit turbulent flow, or a combination oflaminar flow and turbulent flow, while still providing for a consistentdesired flow rate or range of flow rates.

As shown, the flow restricting device 1200 includes a flow restrictionheating arrangement surrounding the flow passage 1215 in the flowrestricting element 1240. The heating arrangement 1270, which may beformed in the flow restricting element 1240, around the flow restrictingelement (e.g., between an outer surface of the flow restricting elementand an inner surface of the body cavity 1219), or around the body member1210 in alignment with the flow passage. A wide variety of flowrestricting heating arrangements may be utilized, including, forexample: one or more heating circuits configured to receive a currentfor heating the flow restricting element, or one or more heat tracepassages for passing heated fluid (e.g., steam) through or around theflow restricting element. The flow restricting element 1240 may beprovided as an insert for installation in the body cavity 1219, similarto the embodiment of FIG. 6. Alternatively, the flow restricting element1240 may be integrally formed with the body 1210, similar to theembodiment of FIG. 7. In either case the flow restricting element may beformed using additive manufacturing (e.g., 3D printing) which may bewell suited to form heat trace or circuit receiving passages in oraround the flow restricting element.

While the controller(s) may be separate from, and physically andelectrically tethered to, the flow sensing element(s), in otherembodiments, a flow sensing element may be provided in a self-containedmodule, for example, for ease of installation in a fluid system, with anenclosure containing the flow sensing device (with external connectorsfor connecting the flow sensing device with the fluid system) and thecontroller. The controller may be configured to communicate (e.g., bywired or wireless communication) with an external device (e.g., server,router, computer, tablet, smartphone) to deliver information about thefluid flow conditions (e.g., pressure, temperature, flow rate).Additionally or alternatively, the module may be provided with a userinterface for providing information about the fluid flow conditions atthe module (e.g., using an LED array or LCD display screen).

FIGS. 10A-11B illustrate various views of an exemplary fluid monitoringmodule 500, including an enclosure 501 formed from a housing 502 and acover 503 (secured together, for example, using bolts or otherfasteners) enclosing a flow sensing device 505 and controller 550. Theflow sensing device 505 may, for example, be similar to any of the flowsensing devices 100 a-f described herein, and may be provided with endconnectors 506 extending through openings in the enclosure 501. Gasketsor other such seals 504 (FIG. 11A) may surround the end connectors 506in the openings, for example, to prevent moisture or other contaminantsfrom entering the enclosure. While the end connectors may be provided ina variety of locations and orientations, in the illustrated embodiment,the end connectors 506 extend from a common wall of the enclosure, forexample, to facilitate installation into an existing fluid system. Asshown in FIGS. 10C and 11A, the flow sensing device 505 may be providedwith elbow fittings or other such connectors and adapters to positionthe end connectors 506 at the desired location and orientation. In onesuch example, the end connectors 506 of the module 500 may be spaced andoriented to corresponding with a conventional flow rate measuring device(e.g., a rotameter-style flow rate measuring device), such that theconventional flow rate measuring device of an existing system may beeasily replaced with the module 500. In another embodiment (not shown),the end connectors may extend axially from the fluid monitoring module,for example, to facilitate inline installation of the flow sensingdevice, or of multiple flow sensing devices with multiple parallel,closely spaced fluid lines. In still other embodiments, the endconnectors may be offset from each other and may extend in oppositedirections from opposite sides of the housing, or perpendicularly fromadjacent sides of the housing.

While the module may be provided with external wiring for connectionwith an external power source (e.g., wall outlet), the module 500 mayadditionally or alternatively include one or more batteries 560, asshown in FIG. 11A, electrically connected with the controller 550 topower the controller hardware (e.g., processor, transmitter, LEDs) andsensors 520, 530 of the flow sensing device 505. As shown, the batteries560 may be disposed in a sleeve 561, for example, to protect andsecurely position the batteries. In some embodiments, the module may beprovided with rechargeable batteries that may be recharged, for example,by electrically connecting external wiring of the module to an externalpower source. Additionally or alternatively, the enclosed batteries mayserve as a back-up power source (e.g., in the event of a building powerfailure), with the module primarily operating off of an external powersource. As shown in FIG. 10C, a spacer bracket 509 may be providedwithin the enclosure 501, for example, to secure the internal componentsof the module in a desired position.

The exemplary flow sensing device assembly 505 includes upstream anddownstream sensors 520, 530 installed in upstream and downstream sensorports 513, 514 of a body member 510. The sensors 520, 530 are connected(e.g., by wiring within the module enclosure) to the controller 550 totransmit pressure and temperature indicating signals to the controller.The controller 550 is configured to process the pressure and temperatureindicating signals, for example, to determine pressure, temperature,and/or flow rate of fluid passing through the flow sensing device,and/or to provide a measured output of any one or more of theseparameters.

In the embodiment of FIGS. 10A-11B, the sensor ports 513, 514 of thebody 510 are oriented to face the sides of the housing 502.Alternatively, as shown in FIG. 12, the sensor ports 513′, 514′ of thebody 510′ may be oriented to face the housing rear wall and the cover503′, allowing the width of the enclosure to be reduced. Additionally oralternatively, the battery size may be reduced (e.g., replacing two Ccell batteries 560 with one D cell battery 560′, as shown in FIG. 12) toallow the height of the enclosure to be reduced.

The module may be provided with external wiring for a wired connectionwith an external device (e.g., computer). Additionally or alternatively,as shown, the module 500 may be provided with a wireless transmitter(e.g., provided on a circuit board of the controller 550) for wirelesslytransmitting fluid data to a remote device (e.g., server, router,computer, tablet, smartphone), for example, using direct or indirectwireless communication with the remote device. The transmitter may beconfigured to communicate using any number of suitable wirelesscommunication protocols and capabilities, such as, for example, WiFi,Bluetooth, ZigBee, RFID, NFC, and wireless USB communication. As shown,the module 500 may include an external antenna 555, electricallyconnected with the controller transmitter, for enhanced wirelesscommunication with a remote device. In an exemplary system, a WiFigateway router may be provided for wireless communication with one ormore modules, for example, to establish a browser interface (which mayeliminate the need for desktop software), facilitate commissioning offield devices, establish data system/cloud interfaces, and provide forsimplified troubleshooting and diagnostics.

To facilitate commissioning and control (e.g., power on/off,synchronization) of the module, the module may be provided with a userinterface, such as, for example, one or more knobs, switches or buttons.In the illustrated embodiment, the module 500 includes an external, userdepressible button 507 disposed in an opening in the cover 503 andpositioned for actuation of a button switch 557 on the controller 550,which may be actuated, for example, to turn on the controller, to turnoff the controller, or to commission/synchronize the controller. Thebutton 507 may be provided in a transparent or translucent material, toprovide illumination from one or more LEDs 558 on the controller 550,which may be illuminated, for example, to provide user indication of acontroller status (e.g., power on/off, connectivity, recognized useractuation). The LEDs 558 may provide multi-color illumination (either byproviding multiple LEDs each having different color illumination, or oneor more multi-color LEDs) and/or pulsed illumination, for example, toidentify multiple distinguishable status conditions.

In addition to, or instead of, wired or wireless communication with anexternal device, the module may be provided with a user interfaceconfigured to display fluid flow data on the module. FIG. 13Aillustrates an exemplary module 500 a including a user interface displayscreen 559 a (e.g., LCD, OLED) disposed on an outer surface of theenclosure (e.g., on the cover 503 a) and connected in circuitcommunication with the module controller, for display of one or morefluid conditions (e.g., flow rate, temperature, pressure).Alternatively, to provide a simpler output display, an LED array 559 b,559 c may be used to provide a digital display (e.g., one or morenumerical digits), as shown in FIG. 13B, or a multi-bar proportionalreadout display (e.g., three or more LEDs showing proportional levels offlow rate, pressure, and/or temperature), as shown in FIG. 13C. In anexemplary embodiment of the present disclosure, digital or multi-bar LEDdisplays may utilize multi-color LEDs to display multiple types of fluiddata using the same set of LEDs. For example, the digital LED display559 b of FIG. 13B may provide for illumination of the corresponding LEDsin a first color (e.g., white) to identify a measured flow rate, asecond color (e.g., red) to identify a measured pressure, and a thirdcolor (e.g., green) to identify a measured temperature. Similarly, thedigital LED display 559 c of FIG. 13C may provide for illumination ofthe corresponding LEDs in a first color (e.g., white) to identify aproportional flow rate level, a second color (e.g., red) to identify aproportional pressure level, and a third color (e.g., green) to identifya proportional temperature level. A user may selectively toggle betweenfluid data by actuating a user interface (e.g., button or knob), or thedisplay may be configured to automatically periodically switch (e.g.,every 3-10 seconds) between the different fluid flow data.

In one or more exemplary embodiments, a fluid monitoring module, suchas, for example, any of the modules described herein, may be configuredto provide a number of desired properties and conditions, including. Forexample, a fluid monitoring module may be configured to provide typicaldesired sample stream and bypass flow ranges, including, for example,gas flow rates of about 0.05 to 20 SLPM (analyzer) or liquid flow ratesof about 0.05-20 LPM (bypass). An exemplary fluid monitoring module maybe configured to provide flow measurement accuracy of less than about10% of full scale (e.g., about +/−5% accuracy), and may be configured toprovide excellent repeatability and stability. An exemplary fluidmonitoring module may, for example, be rated for use from about −20 C to80 C, or at a maximum ambient temperature of about 85 C. An exemplaryfluid monitoring module may, for example, be rated for operatingpressures between about 50 psig and 150 psig, and may be rated for 1900psig proof or 3500 psig burst. Exemplary materials of construction mayinclude, for example, 316 stainless steel, Hastelloy, FKM, and FFKM. Anexemplary fluid monitoring module may include appropriate safetyratings, including, for example, class 1 division 1 for the transmitter,class 1 division 2 for the gateway, ATEX Zone 1, and/or IECEx Zone 1. Anexemplary fluid monitoring module may be configured for 2.4 GHz meshwireless communication. An exemplary fluid monitoring module may includea disposable lithium battery with at least a five year life. Anexemplary fluid monitoring module may be rated for a lag time of T90=5seconds maximum for 0.2 SLPM gas flow.

In one or more exemplary embodiments, a fluid monitoring module, suchas, for example, any of the modules described herein, may be used in avariety of applications, including, for example, any one or morelocations in a process analytical system. Examples include fieldstations, fast loop systems, grab sampling locations, calibration andswitching locations, sample conditioning locations, gas and/or utilitiesanalyzers, and sample disposal locations.

According to another aspect of the present disclosure, a flow sensingdevice may be configured to facilitate removal of a flow restrictingelement without removing the flow sensing device from the system, forexample, to replace a damaged or contaminated flow restricting element,to facilitate inspection of the flow restricting element, or to replacethe flow restricting element with a second flow restricting elementproviding a different flow condition (e.g., different flow rate). In onesuch embodiment, the flow sensing element may be provided with first andsecond end connections facilitating disconnection and removal of theflow sensing element from the inlet/outlet ports and theupstream/downstream sensor ports. As one example, first and second endconnections of a flow sensing element may include zero clearancefittings (e.g., gasketed VCO fittings manufactured by Swagelok Co.)facilitating removal and reinstallation/replacement of the flow sensingelement without repositioning the ported ends of the flow sensingdevice.

FIG. 14 illustrates an exemplary fluid monitoring module 600 including aflow sensing device 605 configured to facilitate removal of a flowrestricting element 640. The exemplary flow sensing device 605 includesfirst and second T-shaped body members 610-1, 610-2 including first runports defining laterally outward extending inlet and outlet ports 611,612, second run ports defining laterally inward extending upstream anddownstream sensor ports 613, 614, and branch or connecting portsdefining axially extending first and second restrictor connections 618,619 for connecting with first and second end connectors 648, 649 of theflow restricting element 640. Upstream and downstream sensors 620, 630(which may be similar to the sensors 120, 130, 520, 530 of theembodiments of FIGS. 1-13) are sealingly installed in the upstream anddownstream sensor ports 613, 614.

The inlet port 611, upstream sensor port 613 and first restrictorconnection 618 of the first body member 610-1 are connected in fluidcommunication by an internal T-shaped upstream passage 616 of the firstbody member 610-1, and the outlet port 612, downstream sensor port 614,and second end connection 619 are connected in fluid communication by aninternal T-shaped downstream passage 617 of the second body member610-2. The ports may include any suitable fluid system connectors,including, for example, one or more tube fittings, face seal fittings,threaded pipe ends, or weld ends.

The upstream and downstream passages 616, 617 are connected by a flowrestricting passage 615 in the flow restricting element 640. Asdescribed above, the flow restricting passage 615 may take one or moreof a variety of forms including, for example, one or more straight orconvoluted passages or one or more sintered or other such flowrestricting materials. The passage(s) may be formed using one or more ofa variety of processes, including machining or additive manufacturing.The flow restricting passages may be formed in one or more inserts 641(e.g., plugs, plates, etc.) retained in a coupling body 642 to which thefirst and second end connections 648, 649 are attached (e.g., by weldingor integrally forming). In one embodiment, the flow restrictinginsert(s) may be removable from the coupling body for replacement withalternative flow restricting inserts providing different flow rates,flow paths, materials, or other such properties. In other embodiments,the flow restricting component may be integrally or monolithicallyformed with the coupling body, such that the entire flow restrictingelement is replaced. In other embodiments, the flow restricting element640 may be replaced with a flow restricting element having a differentaxial length, for example, to adjust the offset of the inlet and outletports 611, 612. In still other embodiments, variations in the offset ofthe inlet and outlet ports may be accommodated by providing the inletand outlet ports with flexible end connections, such as, for example,hose connections.

The first and second end connections 648, 649 of the exemplary flowrestricting element 640 include zero clearance connectors for connectionwith mating zero clearance connectors of the first and secondconnections 618, 619 of the first and second body members 610-1, 610-2.An exemplary zero clearance fitting is a VCO fitting, manufactured bySwagelok Co. In one embodiment, the coupling body 642 is provided withmale threaded body connectors, and the body members 610-1, 610-2 areprovided with welded glands and captured female threaded nuts forcoupling with the male threaded body connectors. In another embodiment,the body members 610-1, 610-2 are provided with male threaded bodyconnectors, and the coupling body 642 is provided with welded glands andcaptured female threaded nuts for coupling with the captured nuts. Instill another embodiment, the coupling body 642 is provided with a malethreaded body connector for connecting with a captured female nut on oneof the first and second body members, and a captured female threaded nutfor connecting with a male threaded body connector on the other of thefirst and second body members. This arrangement may provide an assurancethat the flow restricting element is installed in the correctdirectional orientation.

The flow restricting element may be provided as a multiple piecesubassembly including one or more connectors detachable to facilitateremoval and/or replacement of the flow restricting insert from thecoupling body. FIG. 14A illustrates an exemplary flow restrictingelement 640 a with a two-piece body including a male threaded gland 643a joined with a female threaded connector 644 a to form the couplingbody 642 a. A flow restricting insert 641 a, defining a flow restrictionor orifice 615 a is received in a recess in the connector 644 a, and theexemplary gland 643 a includes a face seal O-ring 645 a that sealsagainst the retainer body recess and the insert. The gland 643 a retainsa female threaded zero clearance fitting nut 648 a for connecting with amale threaded zero clearance fitting body on a first body member of theflow restricting device, and the retainer body defines a male threadedzero clearance fitting body 649 a for connecting with a female threadedzero clearance fitting nut on a second body member of the flowrestricting device. To repair (e.g., clean) or replace the flowrestricting insert 641 a, the fitting nut 648 a is unthreaded from themale threaded fitting body of the device (not shown), and the connector644 a is unthreaded from the female threaded nut of the device (notshown) to remove the flow restricting element subassembly 640 a from thedevice. The gland 643 a is then unthreaded from the connector 644 a forremoval and repair/reinstallation or replacement of the flow restrictinginsert 641 a. Alternatively, the entire flow restriction elementsubassembly 640 a may be replaced.

FIG. 14B illustrates another exemplary flow restricting element 640 bhaving a two-piece body 642 b including a first male threaded zeroclearance connector 643 b having a female threaded (e.g., NPT threads)end and a second male threaded zero clearance connector 644 b having amating male threaded (e.g., NPT threads) end joined with the femalethreaded end to form the coupling body. A flow restricting insert 641 bdefining a flow restricting orifice 615 b is received in a recess in thefirst connector 643 b, and may be secured against a counterbore portion645 b of the first connector by an end face 646 b of the male threadedend of the second connector 644 b. To repair (e.g., clean) or replacethe flow restricting insert 641 b, the first and second male connectors643 b, 644 b are unthreaded from corresponding female threaded nuts (notshown) of the device to remove the flow restricting element subassembly640 b from the device. The first and second male connectors 643 b, 644 bmay then be unthreaded from each other for removal andrepair/reinstallation or replacement of the flow restricting insert 641b. Alternatively, the entire flow restriction element subassembly 640 bmay be replaced.

FIG. 14C illustrates an exemplary flow restricting element 640 c with atwo-piece arrangement including a male threaded zero clearance connector643 c joined with a gland 644 c by a female threaded zero clearance nut648 c. A flow restricting insert 641 c, defining a flow restrictingorifice 615 c, is received and sealed between a face seal O-ring 645 cassembled with the male connector 643 c (e.g., retained in an end facegroove of the male threaded end) and a face seal O-ring 646 c assembledwith the gland 644 c (e.g., retained in an end face groove of thegland). In an exemplary embodiment, the male connector 643 c may beaffixed with (e.g., welded to, coupled to, or integrally machined with)a first fitting body defining an first (e.g., inlet, outlet) port and asensor retaining first (e.g., upstream, downstream) sensor port, and thegland may be affixed with (e.g., welded to, coupled to) a second fittingbody defining a second (e.g., inlet, outlet) port and a sensor retainingsecond (e.g., upstream, downstream) sensor port. To repair (e.g., clean)or replace the flow restricting insert 641 c, the female threaded nut648 c is unthreaded from the male threaded connector 643 c, and the flowrestricting insert 641 c is slid out of engagement from the face sealO-rings 645 c, 646 c for repair/reinstallation or replacement of theflow restricting insert 641 c.

In other embodiments, the flow restricting element may be provided as asingle piece body having a flow restriction assembled with or integralwith the body. FIG. 14D illustrates an exemplary flow restrictingelement 640 d with a single piece body 642 d including first and secondmale threaded zero clearance connections 648 d, 649 d and a flowrestriction 615 d integrally formed along a through bore 647 d (e.g.,centrally located, as shown). To repair (e.g., clean) or replace theflow restriction 615 d, the first and second male connections 648 d, 649d are unthreaded from corresponding female threaded nuts (not shown) ofthe device to remove the flow restricting element 640 d from the device.

In other embodiments, a flow restricting insert may be assembled with asingle piece flow restricting element body, for example, using athreaded engagement, press fit engagement, or retaining clip engagement,and may in some embodiments include a gasket or seal to prevent leakagebetween the flow restricting element body and an outer periphery of theinsert. FIG. 14E illustrates an exemplary flow restricting element 640 ewith a single piece body 642 e including first and second male threadedzero clearance connections 648 e, 649 e and a press-in orifice disc orapertured insert 641 e (defining orifice 615 e), installed in a throughbore 647 e of the body (e.g., seated against a counterbore in thethrough bore). FIG. 14F illustrates an exemplary flow restrictingelement 640 f with a single piece body 642 f including first and secondmale threaded zero clearance connections 648 f, 649 f and a press-insintered element or porous insert 641 f installed in a through bore 647f of the body (e.g., seated against a counterbore in the through bore)to define a porous flow path 615 f. While the flow restricting insertmay be positioned in a central portion of the through bore, between theend connections, as shown in FIGS. 14E and 14F, in other embodiments,the flow restricting insert may be installed within at least one of theend connections, in an end portion of the through bore. FIG. 14Gillustrates an exemplary flow restricting element 640 g with a singlepiece body 642 g including first and second male threaded zero clearanceconnections 648 g, 649 g and a press-in sintered element or porousinsert 641 g installed in an end portion of the through bore 647 g, inthe first end connection 648 g (e.g., seated against a counterbore inthe through bore) to define a porous flow path 615 g. FIG. 14Hillustrates an exemplary flow restricting element 640 h with a singlepiece body 642 h including first and second male threaded zero clearanceconnections 648 h, 649 h and a restrictor set screw or threadedapertured insert 641 h (defining orifice 615 h) installed in a femalethreaded end portion of the through bore 647 h, in the first endconnection 648 h. FIG. 14I illustrates an exemplary flow restrictingelement 640 i with a single piece body 642 i including first and secondmale threaded zero clearance connections 648 i, 649 i and an orificedisc or apertured insert 641 i (defining orifice 615 i) installed in anend face counterbore of the through bore 647 i, in the first endconnection 648 i (e.g., snap fit or press fit). In one such embodiment,the o-ring seal 645 i of the first end connection 648 i provides a sealbetween the outer periphery of the orifice disc 641 i and thecounterbore.

To repair (e.g., clean) or replace the flow restricting inserts 641 e-h,the first and second male connections 648 e-h, 649 e-h are unthreadedfrom corresponding female threaded nuts (not shown) of the device toremove the flow restricting element 640 e-h from the device. The insert641 e-h may be removed (e.g., unthreaded, pressed) from the body 642 e-hfor cleaning or replacement. Alternatively, the entire flow restrictingelement 640 e-h may be replaced.

Referring back to FIG. 14, the exemplary fluid monitoring module 600includes an enclosure (shown schematically at 601) affixed to (e.g., atleast partially enclosing) the flow sensing device 605 and enclosing acontroller, shown schematically at 650 (which may be similar to thecontroller 550 of the embodiments of FIGS. 10A-13C). The sensors 620,630 are connected (e.g., by wiring within the module enclosure) to thecontroller 650 to transmit pressure and temperature indicating signalsto the controller. The controller 650 is configured to process thepressure and temperature indicating signals, for example, to determinepressure, temperature, and/or flow rate of fluid passing through theflow sensing device, and/or to provide a measured output of any one ormore of these parameters. Similar to the exemplary embodiment of FIGS.10A-13C, the module 600 may additionally be provided with one or moreof: one or more internal batteries 660; a wireless transmitter (e.g.,provided on a circuit board of the controller 650) for wirelesslytransmitting fluid data to a remote device; an external antenna 655,electrically connected with the controller transmitter, for enhancedwireless communication with a remote device; a user interface, such as,for example, one or more knobs, switches or buttons, for example, toturn on the controller, to turn off the controller, or tocommission/synchronize the controller, and one or more display elements(e.g. indicator LEDs and/or display screen), as described in greaterdetail above.

The enclosure 601 may be provided with a cover or lid (not shown) toselectively enclose the flow sensing device 605, while being movable orremovable for exposure of the flow sensing device, for example, tofacilitate removal and/or replacement of the flow restricting element.

Still other arrangements may be utilized to facilitate removal and/orreplacement of a flow restricting element from a flow sensing device.FIG. 15 schematically illustrates a fluid monitoring module 700including a flow sensing device 705 having first and second T-shapedbody members 710 a, 710 b including first run ports defining laterallyoutward extending inlet and outlet ports 711, 712, second run portsdefining laterally inward extending upstream and downstream sensor ports713, 714 (retaining upstream and downstream sensors 720, 730), andbranch ports defining laterally extending first and second connections718, 719, perpendicular to the inlet/outlet and sensor ports 711, 712(i.e., extending outward from the drawing sheet), 713, 714, forconnecting with first and second end laterally extending connectors 748,749 of a U-shaped flow restricting element 740. The U-shaped flowrestricting element 740 includes an axially extending portion definingone or more flow restricting passages 715, which may be formed, forexample, in one or more inserts 741 (e.g., plugs, plates, etc.) retainedin a U-shaped coupling body 742 to which the first and second endconnections 748, 749 are attached (e.g., by welding or integrallyforming). The coupling body 742 may be provided as a multiple pieceassembly including one or more connectors 744 detachable to facilitateremoval and/or replacement of the insert 741 from the coupling body. Inone embodiment, the flow restricting insert(s) may be removable from thecoupling body for replacement with alternative flow restricting insertsproviding different flow rates, flow paths, materials, or other suchproperties. In other embodiments, the flow restricting component may beintegrally or monolithically formed with the coupling body, such thatthe entire flow restricting element is replaced.

The U-shaped configuration of the flow restricting element 740 mayfacilitate removal from the flow sensing device 705 and may facilitatethe use of end connections that are not zero-clearance connections(e.g., fittings that do not use elastomeric seals, for example, to allowfor a wider range of system conditions), including, for example, tubefittings, quick disconnect fittings, and push-to-connect fittings.

According to another aspect of the present disclosure, a fluidmonitoring module may be provided with a flow sensing device arrangedsuch that at least a flow restricting element of the flow sensing deviceis external to a housing of the fluid monitoring module, for example, tofacilitate removal of the flow restricting element without removing,disassembling, or otherwise adjusting the module housing. As oneexample, as shown in FIG. 16A, a fluid monitoring module 400 a may beprovided with a flow sensing device 405 a having first (e.g., upstream)and second (e.g., downstream) sensor ports 413 a, 414 a mounted to themodule enclosure 401 a for electrical connection of retained sensors(which may be similar to the sensors 120, 130, 520, 530 of theembodiments of FIGS. 1-13C) to a controller enclosed within the moduleenclosure 401 a, such that the flow restricting element 440 a (e.g., anyof the exemplary flow restricting elements 640 a-i of FIGS. 14A-I) isdisposed external to the module enclosure 401 a, for example, tofacilitate removal and replacement/repair of the flow restrictingelement 440 a.

In the embodiment of FIG. 16A, the flow sensing device 405 a includesfirst and second T-shaped body members 410 a-1, 410 a-2 including firstrun ports defining laterally outward extending inlet and outlet ports411 a, 412 a, second run ports defining the laterally inward extendingsensor ports 413 a, 414 a, and branch or connecting ports definingaxially extending first and second restrictor connections 418 a, 419 afor connecting with the flow restricting element 440 a. As describedabove, the restrictor connections 418 a, 419 a may be zero-clearanceconnections to facilitate removal of the flow restricting element 440 a.

In another exemplary arrangement, as shown in FIG. 16B, a fluidmonitoring module 400 b includes an externally mounted flow sensingdevice 405 b having first and second T-shaped body members 410 b-1, 410b-2 including first run ports defining axially extending inlet andoutlet ports 411 b, 412 b, second run ports defining axially extendingfirst and second restrictor connections 418 b, 419 b for connecting withthe flow restricting element 440 b (e.g., any of the exemplary flowrestricting elements 640 a-i of FIGS. 14A-I), and branch or connectingports defining laterally inward extending sensor ports 413 b, 414 bmounted to the module enclosure 401 b for electrical connection of theretained sensors (which may be similar to the sensors 120, 130, 520, 530of the embodiments of FIGS. 1-13C) to a controller enclosed within themodule enclosure 401 b.

In another exemplary arrangement, as shown in FIG. 16C, a fluidmonitoring module 400 c includes an externally mounted flow sensingdevice 405 c having first and second T-shaped body members 410 c-1, 410c-2 including first run ports defining laterally outward extending inletand outlet ports 411 c, 412 c, second run ports defining laterallyinward extending first and second (e.g., upstream and downstream) sensorports 413 c, 414 c mounted to the module enclosure 401 c for electricalconnection of the retained sensors (which may be similar to the sensors120, 130, 520, 530 of the embodiments of FIGS. 1-13C) to a controllerenclosed within the module enclosure 401 c, and branch ports definingperpendicular laterally extending first and second restrictorconnections 418 c, 419 c for connecting with a U-bend flow restrictingelement 440 c (which may be similar to the flow restricting element 740of FIG. 15).

Many different arrangements may be utilized to mount the sensor ports ofthe flow sensing device to the module enclosure. FIG. 17 illustrates anexemplary arrangement including a flow sensing device body member 410′including a male threaded sensor port or connector 413′ received througha mounting aperture 408′ in the module enclosure 401′ and securedagainst the module enclosure by a panel nut 481′ threaded with the maleconnector 413′. A sensor 420′ is installed in the sensor port connector413′ and is secured against a counterbore 483′ by a retaining collar485′ extending through the sensor port 413′ to engage a surface of thesensor 420′. A fitting nut 487′ is threadably assembled with the maleconnector 413′ to secure an end portion 486′ of the retaining collar485′, and a wire connector 489′ (e.g., M8 connector) is installed in acentral bore in the retaining collar end portion 486′ to provide aconnection between wiring 423′ from the sensor 420′ and the controller(not shown). Gasket seals 482′, 484′, 488′ (e.g., O-ring seals) may beprovided between the body member 410′ and module enclosure 401′, betweenthe retaining collar 485′ and male connector 413′, and between the maleconnector 413′ and wire connector 489′, for example, to seal the moduleenclosure 401′ from moisture or other contamination. A gasket seal 422′(e.g., O-ring seal) around the sensor 420′ provides a leak tight seal toprevent system fluid leakage past the sensor 420′.

In other exemplary arrangements, as illustrated, for example, in FIG.16D, a fluid monitoring module 400 d may be provided with a flow sensingdevice 405 d having a first body member 410 d-1 with a first (e.g.,upstream) sensor port 413 d mounted to the module enclosure 401 d (e.g.,using the arrangement of FIG. 17) for electrical connection of aretained sensor (e.g., as described above) to a controller enclosedwithin the module enclosure 401 d, and a second body member 410 d-2 witha second (e.g., downstream) sensor ports 414 d spaced apart from themodule enclosure and retaining a sensor (e.g., as described above)electrically connected (e.g., by flexible wiring 452 d extending fromthe second sensor port 414 d to the module enclosure 401 d) to acontroller enclosed within the module enclosure 401 d, such that theflow restricting element 440 d is disposed external to the moduleenclosure 401 d, for example, to facilitate removal andreplacement/repair of the flow restricting element 440 d. The singlesensor port mount arrangement may allow for use of different sized flowrestricting elements (e.g., different offset dimensions between thesensor ports, different lengths of flow restrictions) and/or differentsized module enclosures. Additionally, the single sensor port mountarrangement may facilitate removal of the flow restricting element 440 dfrom the flow sensing device 405 d without using zero clearanceconnections (e.g., to eliminate polymeric seals in the connections), asthe second sensor port is not fixedly mounted.

In still other exemplary arrangements, as illustrated, for example, inFIG. 16E, a fluid monitoring module 400 e may be provided with a flowsensing device 405 e having first and second body members 410 e-1, 410e-2 defining inlet and outlet ports 411 e, 412 e, and first and second(e.g., upstream and downstream) sensor ports 413 e, 414 e spaced apartfrom the module enclosure 401 e and retaining sensors (e.g., asdescribed above) electrically connected (e.g., by flexible wiring 451 e,452 e extending from the first and second sensor ports 413 e, 414 e tothe module enclosure 401 e) to a controller enclosed within the moduleenclosure 401 e, such that the flow restricting element 440 e isdisposed external to the module enclosure 401 e, for example, tofacilitate removal and replacement/repair of the flow restrictingelement 440 e. The detached or remote, wire connected sensor portarrangement may allow for use of different sized flow restrictingelements (e.g., different offset dimensions between the sensor ports,different lengths of flow restrictions) and/or different sized moduleenclosures. Additionally, the wire connected sensor port arrangement mayfacilitate removal of the flow restricting element 440 e from the flowsensing device 405 e without using zero clearance connections (e.g., toeliminate polymeric seals in the connections), as the sensor ports arenot fixedly mounted and thus easily moveable with respect to each other.Additionally, in one such configuration, the module 400 e may beconfigured to easily disconnect from the sensor wiring 451 e, 452 e, forexample, to allow use of the monitoring module with multiple flowsensing devices or to perform maintenance on the monitoring module.

According to another aspect of the present disclosure, a fluidmonitoring module may be configured or adapted to provide separatesensing of fluid conditions in multiple fluid lines, or at multiplelocations in a single fluid line, for example, to monitor changes inpressure over time (e.g., as an indication of filter or fluid linecontamination). In one such arrangement, the flow restriction may beeliminated, with the flow sensing arrangement providing separate sensorengaging flow paths. As one example, as shown in FIG. 18A, a fluidmonitoring module 300 a may be provided with separate first and secondsensing devices 305 a-1, 305 a-2 having first and second (e.g., inletand outlet) ports 311 a-1, 311 a-2, 312 a-1, 312 a-2 and first andsecond sensor ports 313 a-1, 313 a-2 mounted to the module enclosure 301a for electrical connection of retained sensors (as described above) toa controller enclosed within the module enclosure 301 a.

As another example, a fluid monitoring module with an external flowrestricting element may be converted to a fluid monitoring module havingseparate fluid sensing devices by separating the flow restriction withone or more blind or blank coupling members. FIG. 18B illustrates anexemplary fluid monitoring module 300 b, similar to the fluid monitoringmodule 400 a of FIG. 16A, except with the flow restricting elementreplaced with a fluid blocking blind or blank coupling 340 b installedbetween connections 318 b, 319 b of first and second body members 310b-1, 310 b-2, to provide two separate dead-leg fluid monitoringlocations. Alternatively (not shown), separate plugs may be assembled tothe opposed body member connections.

FIG. 18C illustrates an exemplary fluid monitoring module 300 cincluding first and second cross-shaped flow sensing bodies 310 c-1, 310c-2, with sensor ports 313 c, 314 c mounted to the module enclosure 301c, first, axially outward extending ports 311 c-1, 311 c-2, second,laterally outward extending ports 312 c-1, 312 c-2, and axially inwardextending restrictor connections 318 c, 319 c. To use the monitoringmodule 300 c to monitor flow rate, a flow restricting element (e.g., anyof the flow restricting elements 440 a-h of FIGS. 14A-141) may beassembled with the restrictor connections 318 c, 319 c, one of the ports311 c-1, 312 c-1 of the first flow sensing body 310 c-1 may be connectedwith a fluid inlet line, one of the ports 311 c-2, 312 c-2 of the secondflow sensing body 310 c-2 may be connected with a fluid outlet line, andthe two unused ports may be plugged. To use the monitoring module 300 cto monitor two separate fluid locations, a blank or blind coupling 340 c(as shown, for example, in FIG. 18D) or blank/blind insert 341 c (asshown, for example, in FIG. 18E) may be assembled with the restrictorconnections 318 c, 319 c, one of the ports 311 c-1, 312 c-1, 311 c-2,312 c-2 of each of the first and second flow sensing bodies 310 c-1, 310c-2 may be connected with first and second fluid inlet lines, and theothers of the ports of each of the first and second flow sensing bodies310 c-1, 310 c-2 may be connected with first and second fluid outletlines.

According to another aspect of the present disclosure, a fluidmonitoring module may be configured to be provided as a separate,portable device that may be configured to be selectively connected to afluid line for measurement of flow, temperature, and/or pressureconditions, thereby allowing for use of a single fluid monitoring modulefor multiple fluid lines.

FIG. 19 illustrates an exemplary system including a fluid line L with anengineered flow restriction R (e.g., provided in a flow restrictingcoupling, valve, etc.), and a fluid monitoring module 800. The fluidline L includes branch connectors C1, C2 (e.g., quick disconnectcouplings) upstream and downstream of the flow restriction R, forconnection with sensor port connectors 811, 812 of upstream anddownstream sensor ports 813, 814 (e.g., using mating quick disconnectcouplings) of the fluid monitoring module 800. Upstream and downstreamsensors 820, 830 (which may be similar to the sensors described above)are sealingly installed in the upstream and downstream sensor ports 813,814, and are electrically connected to a controller 850 disposed in anenclosure 801 of the fluid monitoring module 800. Similar to theexemplary embodiments of FIGS. 10A-13C, the module 800 may additionallybe provided with one or more of: one or more internal batteries; awireless transmitter (e.g., provided on a circuit board of thecontroller 850) for wirelessly transmitting flow data to a remotedevice; an external antenna, electrically connected with the controllertransmitter, for enhanced wireless communication with a remote device; auser interface, such as, for example, one or more knobs, switches orbuttons, for example, to turn on the controller, to turn off thecontroller, or to commission/synchronize the controller, and one or moredisplay elements (e.g. indicator LEDs and/or display screen), asdescribed in greater detail above.

To monitor the flow conditions of the fluid line L, the upstream sensorport connector 811 is connected with the upstream fluid line branchconnector C1 for measuring the pressure and/or temperature upstream ofthe flow restriction R, and the downstream sensor port connector 812 isconnected with the downstream fluid line branch connector C2 formeasuring the pressure and/or temperature downstream of the flowrestriction R. Corresponding signals are transmitted from the sensors820, 830 to the controller 850 for calculation and identification (e.g.,through a user interface or communication of the data to a remotecomputer) of the pressure, temperature, flow rate, and/or other fluidconditions.

In another embodiment, a fluid monitoring module may be configured tomeasure only pressure and temperature of a fluid, and not flow rate. Insuch an arrangement, the module may be provided with a single sensorport and sensor. FIG. 20 illustrates an exemplary system including afluid line L and a fluid monitoring module 900. The fluid line Lincludes a branch connector C (e.g., a quick disconnect coupling) forconnection with a sensor port connector 911 of a sensor port 913 (e.g.,using mating quick disconnect couplings) of the fluid monitoring module900. A sensor 920 (which may be similar to the sensors described above)is sealingly installed in the sensor port 913 and is electricallyconnected to a controller 950 disposed in an enclosure 901 of the fluidmonitoring module 900. Similar to the exemplary embodiments of FIGS.10A-13C, the module 900 may additionally be provided with one or moreof: one or more internal batteries; a wireless transmitter (e.g.,provided on a circuit board of the controller 950) for wirelesslytransmitting fluid data to a remote device; an external antenna,electrically connected with the controller transmitter, for enhancedwireless communication with a remote device; a user interface, such as,for example, one or more knobs, switches or buttons, for example, toturn on the controller, to turn off the controller, or tocommission/synchronize the controller, and one or more display elements(e.g. indicator LEDs and/or display screen), as described in greaterdetail above. In another application, the single sensor monitoringmodule 900 may be used to sequentially measure pressure at an upstreambranch connector C1 and at a downstream branch connector C2 (see FIG.16) to sequentially measure pressure upstream and downstream of anengineered flow restriction R in the fluid line L, thereby enabling thecontroller 950 to calculate a flow rate in the fluid line by using onlyone sensor.

In another embodiment, a portable, selectively connectable fluidmonitoring module may include a bypass flow path with a flow restrictingpassage between upstream and downstream sensor ports, thereby allowingfor the elimination of the flow restriction from the fluid line, forexample, to minimize contamination or erosion of the flow restriction.

FIG. 21 illustrates an exemplary system including a fluid line L and afluid monitoring module 1000. The fluid line L includes upstream anddownstream branch connectors C1, C2 (e.g., quick disconnect couplings)for connection with inlet and outlet connectors 1011, 1012 (e.g., matingquick disconnect couplings) of the module 1000. The module 1000 furtherincludes an upstream sensor port 1013 connected to the inlet connector1011 by an upstream passage 1016, and a downstream sensor port 1014connected to the outlet connector 1012 by a downstream passage 1017.Upstream and downstream sensors 1020, 1030 (which may be similar to thesensors described above) are sealingly installed in the upstream anddownstream sensor ports 1013, 1014 and electrically connected to acontroller 1050 disposed in an enclosure 1001 of the fluid monitoringmodule 1000. The upstream and downstream passages 1016, 1017 areconnected by a flow restricting passage 1015. The inlet and outletconnectors 1011, 1012, upstream and downstream sensor ports 1013, 1014,internal passages 1016, 1017, and flow restricting passage 1015 may beprovided in a flow sensing device 1005 assembled with the moduleenclosure 1001, as shown in the many exemplary embodiments describedherein.

Similar to the exemplary embodiment of FIGS. 10A-13C, the module 1000may additionally be provided with one or more of: one or more internalbatteries; a wireless transmitter (e.g., provided on a circuit board ofthe controller 1050) for wirelessly transmitting flow data to a remotedevice; an external antenna, electrically connected with the controllertransmitter, for enhanced wireless communication with a remote device; auser interface, such as, for example, one or more knobs, switches orbuttons, for example, to turn on the controller, to turn off thecontroller, or to commission/synchronize the controller, and one or moredisplay elements (e.g. indicator LEDs and/or display screen), asdescribed in greater detail above.

To monitor the flow conditions of the fluid line L, the inlet connector1011 of the module is connected with the upstream fluid line branchconnector C1 and the outlet connector 1012 is connected with thedownstream fluid line branch connector C2. A shutoff valve V may bedisposed in the fluid line L between the upstream and downstream branchconnectors C1, C2, and may be shut off to bypass all fluid line flowthrough the fluid monitoring module 1000. Alternatively, switchingvalves (shown in phantom at V1, V2) may be used to divert fluid flowfrom the fluid line L through the fluid monitoring module 1000. Theupstream sensor 1020 measures the pressure and/or temperature upstreamof the flow restricting passage 1015, and the downstream sensor 1030measures the pressure and/or temperature downstream of the flowrestricting passage 1015. Corresponding signals are transmitted from thesensors 1020, 1030 to the controller 1050 for calculation andidentification (e.g., through a user interface or communication of thedata to a remote computer) of the pressure, temperature, flow rate,and/or other fluid conditions.

In still another embodiment, a portable fluid monitoring module may beprovided without fluid components (e.g., ports, connectors, passages),and with a wireless transceiver for communicating wirelessly with one ormore fluid sensors integrated into the fluid line of a system, such thatan operator may perform a fluid monitoring operation at one or morelocations in a fluid system by bringing the portable fluid monitoringmodule into proximity with the integrated fluid sensor(s).

FIG. 22 illustrates an exemplary system including a fluid line L with anengineered flow restriction R (e.g., provided in a flow restrictingcoupling, valve, etc.), and a portable fluid monitoring module 1400. Thefluid line L includes fluid sensors 1420, 1430 (which may be similar tothe sensors described above) upstream and downstream of a flowrestriction 1415. While the fluid sensors 1420, 1430 and flowrestriction 1415 may be integrated into the fluid line L, in anexemplary embodiment, the fluid sensors and flow restriction may beprovided in a separate flow sensing device 1405 including connectors1411, 1412 (e.g., zero clearance fittings) configured to facilitatecoupling and decoupling from the fluid line L. The flow restriction 1415may be provided in a flow restricting element 1440 having connectors1448, 1449 to facilitate removal of the flow restricting element fromthe flow sensing device 1405 (e.g., for maintenance or replacement witha different flow restricting element having different sizing and/or flowcharacteristics.

The fluid monitoring module 1400 includes a transceiver 1470 configuredto wirelessly communicate (e.g., RFID, Bluetooth, NFC, or other suchwireless communication), for example, through an antenna 1475, with thefluid sensors 1420, 1430, when the fluid monitoring module 1400 is inproximity with the sensors 1420, 1430. Wireless communication may beautomatically initiated when in proximity (e.g., as a result of periodicquery or ping transmissions by the transceiver), or by actuation of abutton or other such user interface. The transceiver 1470 communicatesreceived data signals corresponding to the fluid system (e.g.,identification codes, upstream/downstream pressure, temperature, timestamp) to a controller 1450 in the module enclosure 1401. Similar to theexemplary embodiment of FIGS. 10A-13C, the module 1400 may additionallybe provided with one or more of: one or more internal batteries 1460; awireless transmitter (e.g., provided on a circuit board of thecontroller 1450) for wirelessly transmitting flow data to a remotedevice; an external antenna 1455, electrically connected with thecontroller transmitter, for enhanced wireless communication with aremote device; a user interface, such as, for example, one or moreknobs, switches or buttons, for example, to turn on the controller, toturn off the controller, or to commission/synchronize the controller,and one or more display elements (e.g. indicator LEDs and/or displayscreen), as described in greater detail above.

In one embodiment, the fluid monitoring module 1400 may be a smart phoneor other such portable computing device that may be provided with asoftware or web-based application configured to initiate communicationwith the sensors 1420, 1430, process the received data signals, displaydata related to the fluid system conditions, and/or transmit fluid datato a remote system.

According to another aspect of the present disclosure, a fluidmonitoring module having a controller configured for communicating withan external device may be further configured to receive datatransmissions from other proximate fluid system components forcommunication of properties and characteristics of these proximate fluidsystem components to an external device for tracking or monitoring. Asone example, a portable sample cylinder selectively connected to a fluidsystem (e.g., for obtaining a grab sample for off-site laboratoryanalysis) may include communication circuitry (e.g., RFID tag)configured to communicate directly or indirectly with a fluid monitoringmodule of the fluid system when the sample cylinder is proximate to thefluid monitoring module. In one example, the fluid monitoring module mayinclude or be connected with (e.g., by a wired or wireless connection)an RFID reader configured to initiate wireless communication (e.g., nearfield communication, Bluetooth® communication, or other such short rangewired or wireless communication) with an RFID tag or transmitterprovided with the sample cylinder when the sample cylinder is broughtinto range of the fluid monitoring module (e.g., by responding to aperiodic query or ping from the reader). In other embodiments,communication between the RFID tag/transmitter and the RFID reader maybe initiated by a user operated push button switch, or by a switch thatis automatically activated when the sample cylinder is connected to thefluid system or when a valve is opened to fill the cylinder.

FIG. 23 schematically illustrates an exemplary system including a fluidline L with which a fluid monitoring module 1300 (e.g., any of the fluidmonitoring modules described herein) is installed. The fluid line Lincludes a branch connector C to which a sample cylinder 1370 may beconnected (e.g., by a quick disconnect coupling connection), forexample, for obtaining a grab sample of the fluid in the fluid line. Thesample cylinder 1370 includes an RFID tag/transmitter 1375 forcommunicating data regarding the sample cylinder (e.g., serial/IDnumber, time stamp associated with time of connection to fluid line L)to an RFID reader 1380 provided with or connected to the fluidmonitoring module 1300. The data received by the RFID reader 1380 may becommunicated to the controller 1350 of the module 1300 (e.g., by a wiredor wireless connection between the controller and the RFID reader) andcompiled with other contemporaneous fluid system data collected by thecontroller (e.g., flow rate, pressure, temperature of fluid in the fluidline as measured by sensors 1320, 1330, serial/ID number of the module1300), and wirelessly communicated via transmitter antenna 1355 to anexternal device, for example, via a wireless gateway 1390, as powered,for example, by module battery 1360. Such an arrangement allows for realtime tracking of a grab sampling operation without providing separatepower and wireless transmission capability to the grab samplearrangement, by using the fluid monitoring module as a hub for such datacollection and wireless communication.

In other applications, other data may be collected and communicated viathe fluid monitoring modules. For example, operator identification data(e.g., as collected from a user ID RFID tag) and an associated timestampmay be transmitted to the controller when one or more operations areperformed, such as, for example, grab sampling, maintenance, systemshutoff, etc.

The inventive aspects have been described with reference to theexemplary embodiments. Modification and alterations will occur to othersupon a reading and understanding of this specification. It is intendedto include all such modifications and alterations insofar as they comewithin the scope of the appended claims or the equivalents thereof

We claim:
 1. A flow sensing device comprising: a first body memberdefining an inlet port, an upstream sensor port, and a first connectingport; a second body member defining an outlet port, a downstream sensorport, and a second connecting port; a flow restricting element defininga flow restricting passage and including a first end connection coupledto the first connecting port and a second end connection coupled to thesecond connecting port, such that the flow restricting passage isdisposed between the inlet port and the outlet port, and between theupstream sensor port and the downstream sensor port; a first fluidsensor assembled with the upstream sensor port; and a second fluidsensor assembled with the downstream sensor port.
 2. The flow sensingdevice of claim 1, wherein the flow restricting passage is configured toprovide laminar flow.
 3. The flow sensing device of claim 1, wherein thefirst and second end connections comprise zero clearance connectors. 4.The flow sensing device of claim 1, wherein the first and second endconnections comprise O-ring face seal fittings.
 5. The flow sensingdevice module of claim 1, wherein the first and second connecting portsextend laterally from the first and second body members in a firstdirection, and the flow restricting element is substantially U-shaped.6. The flow sensing device of claim 1, wherein the flow restrictingelement comprises at least a first coupling member defining at least oneof the first and second end connections.
 7. The flow sensing device ofclaim 6, wherein the flow restricting passage is integrally formed inthe first coupling member.
 8. The flow sensing device of claim 6,wherein the flow restricting passage is defined by a flow restrictinginsert assembled with the first coupling member.
 9. The flow sensingdevice of claim 8, wherein the flow restricting insert is disposed in athrough bore between the first and second end connections.
 10. The flowsensing device of claim 8, wherein the flow restricting insert comprisesan apertured plate.
 11. The flow sensing device of claim 8, wherein theflow restricting insert comprises a threaded apertured insert installedin a female threaded portion of the first coupling member.
 12. The flowsensing device of claim 8, wherein the flow restricting insert isdisposed in one of the first and second end connections.
 13. The flowsensing device of claim 6, further comprising a second coupling memberjoined with the first coupling member and defining the other of thefirst and second end connections.
 14. The flow sensing device of claim13, wherein the flow restricting passage is defined by a flowrestricting insert captured between the first and second couplingmembers.
 15. A fluid monitoring module comprising: a flow sensing deviceincluding: a first body member defining an inlet port, an upstreamsensor port, and a first connecting port; a second body member definingan outlet port, a downstream sensor port, and a second connecting port;a flow restricting element defining a flow restricting passage andincluding a first end connection coupled to the first connecting portand a second end connection coupled to the second connecting port, suchthat the flow restricting passage is disposed between the inlet port andthe outlet port, and between the upstream sensor port and the downstreamsensor port; a first fluid sensor assembled with the upstream sensorport; and a second fluid sensor assembled with the downstream sensorport; and a controller in circuit communication with the first andsecond fluid sensors for receiving at least one of pressure indicatingsignals and temperature indicating signals from each of the first andsecond fluid sensors, and for measuring fluid data based on the receivedsignals.
 16. The fluid monitoring module of claim 15, further comprisinga wireless transmitter for wirelessly communicating the fluid data fromthe controller to a remote device.
 17. The fluid monitoring module ofclaim 15, wherein the fluid data comprises at least one of fluidpressure, fluid temperature and fluid flow rate.
 18. A fluid monitoringmodule comprising: an enclosure; a fluid sensing device assembled withthe enclosure, the fluid sensing device including: a first body memberdefining a first end port, a first sensor port, and a first connectingport; a second body member defining a second end port, a second sensorport, and a second connecting port; a first fluid sensor assembled withthe first sensor port; and a second fluid sensor assembled with thesecond sensor port; and a controller disposed within the enclosure andin circuit communication with the first and second fluid sensors forreceiving at least one of pressure indicating signals and temperatureindicating signals from each of the first and second fluid sensors, andfor measuring fluid data based on the received signals; wherein thefirst end port, the second end port, the first connecting port, and thesecond connecting port are external to the enclosure.
 19. The fluidmonitoring module of claim 18, further comprising a flow restrictingelement defining a flow restricting passage and including a first endconnection coupled to the first connecting port and a second endconnection coupled to the second connecting port.
 20. The fluidmonitoring module of claim 18, further comprising at least one blindcoupling assembled with the first and second connecting ports to providetwo separate dead-leg fluid monitoring locations at the first and secondend ports.